Frictional body for couplings and the like and method of making same



Fb. 1932. l H, KATTwlNkEL y 1,846,560

FRICTIONAL BODY- FOR COUPLINGS AND THE LIKE AND METHOD OF MAKING SAME Filed March 17.' 1927 2 sheets-Sheet 1 Ike/enfor;

l, 6,560 rRIcTIoNAL sony For:A coUPLINGs AND THELI/KE AND uE'rHoD oF MAKI'NG SAME Feb. 23, 1932.

H. KATTWINKEL Fnea aaron 17. 1927 2 sheets-sheet 2 f ety Patented eb. 23, 1932 l UNITED STATES PATENT OFFICE me mmm-Knr., or coswre, GERMANY rRIcrIoNAL BODY non cournmssnnn rnnmxn AND METHOD or MAKING sum 'Application meanaren 17, 19a?, serial. No. 176,260, and in eerinany Mann 17, 192e.

lln couplings constructed' according` to the present practice iibrous materials of organic or inorganic nature are more' and more being used tor brake blocks'or brake coverings, said 5 fibrous materials consisting of a texture which is impregnated with varnish, artificial resin, water-glass or the like and hardened by drying and by applying pressure and heatthereto y after being thus impregnated. Brake l@ blocks orxcoverings of this kind have heretolore generally been secured to their carrier by means of rivets or the like. llt has also been proposed in case' ot couplings with laminated coupling members to accomplish the connection between the brake covering'and the carrier, which ordinarily consists of a disc ot sheet steel, 4by providing holes --on said disc and lling these holes with punched out pieces ot the' impregnated texture befgre ture are thereupon nlrmly secured to the disc ,by lupsetting and subsequent hardening.

This procedure is inconvenientJ` and' cumbersoine and in addition has the disadvantage, that the available frictioiialsurface for given dimensions of the disc-'shaped carrier cannot fully be'utilized for the frictional edect, because the perforations of the disc-shaped carrier serving'for the reception ot'the several pieces of the frictional material cannot be ar- Y ranged too closely adjacent to each other,

because this would essentially reduce the mechanical strength of the said carrier, whose strength is mainly based upon the coherence ot the relatively small partsintermediate the perforations. Ai: further disadvantage of the frictional brake 'blocks or brake vcoverings which are made according to the known processes consists'itherein, that the several pieces of the l'rictional material will easily become loose thereby givin rise to troubles.

According to this invention these disadvantages are avoided .by applying` the frictional covering as aplastic mass a -continuous layer extending essentially over the entire surface of the disc-shaped carrier, whereby a firm connection with the said carrier and the covering will be brought about :by pressing said mas'sdnto said disc and more particularly' into theA perforations provided hardening. y These pieces ot impregnated textherein. This is preferably done in sucha manner that the disc-shaped carrier is' covered .by the rictional material on both of its sides, v vso that the two layers of said material will be united with each' `other at the. places ofi'w the perforations of the disc-shaped-carrier, thusproviding an especially strongconnection Aof said mass with said carrier. i

rlthe accompanying drawings' show AVtwo 'forms of constructions of the brake bloclr or zijn@ brake covering made according to the process forming part ofthis invention. ln the drawings, Fig. l represents a completed frictional disc made according to this invention, the

under portion' ot this gure being a view of 55 Y the-completed trictional 'covering and the upper portion showing the respective part ont the disc-shaped ycarrier before application of 'the frictional material.

Fig. 2 is a section through the disc-shaped 79 carrier along the line lll-lll ot Fig.. l, while llig. 3 shows a detail on an enlarged scale.

.l41 ig. 4 represents a portion of a rictional -body made according to this invention, said friction'al!- body being of ring-sha ed con` formation 'g the middle part of this glue heing a view of the'completed frictional cover- ,ing, while the outer parts o this figure show .the disc-shaped carrier in uncovered condi-. A

tion. f s@ Fig. 5 is a section along the line V-V ot Fig. 6 a section "along the line VI-V of Fig. 4, and v Fig. 'Z represents partly'a section'andpart- 85 ly a side view showing-.the mode'of connection` of two opposed pieces of the covering together withthedisc-shapeccarrier. A

In vthe construction according to Figs. 1 to 3, whereby the carrier for the fritional 90 material for-ms a circular disc with a. relaf, tively small central laperture, thel frictional covering; is preferably applied in such a manner, that the disc '2, which may be made from sheet steel,.'is provided with a large number 95 of perforations -1 and that thevfrictional covering 3 is applied on hoth'sides of said disc. This rictional -covering consists inthe preferred construction cfa mixture of asbestos p -bers anda agent such as for inm9 stance artificial resin produced by the condensation of a phenol with formaldehyde, and is added in dissolved condition to said asbestos fibers. This mass, which is preferably applied to the disc-shaped carrier in the form of discs of ring-shaped conformation corresponding tothe inal shape to be given to the frictional covering, or in any case in the form of a greater coherent surface, is still fully lastic before hardening, so that it may easi y be pressed into the perforations l of the disc-shaped carrier 2. The two layers will thus come into intimate contact with each other within the perforations, as may be seen from Fig. 3, and therefore rmly adhere to each other. After hardening of the mass, which takes place in the ordinary manner at increased temperature, preferably maintaining the pressure applied for pressing said mass into the perforations of the disc-shaped carrier, the two layers of the frictional coverin will be intimately welded witheach other, so that the frictional covering will positively be prevented from becoming loose even, if the heaviest strains are imposed thereon. After hardening of the covering the frictional disc is preferably smoothly ground upon both sides in order to bring about an intimate frictional contact with the adjacent plates of the coupling which ordinarily consist of bare steel discs, and in order to obtain a construction having the smallest possible dimensions in axial direction;

Instead of the above-mentioned plastic mixture of asbestos fibers and artificial resin of course also frictional masses may be employed which consist of other fibrous materials and bindin agents. The frictional material ma also e applied in the form of a texture w ich is impregnated with a hardening agentz because the frictional material will in this form also be of sufficient plasticitybeforehardening in order to fill up the perforations in the disc-sha ed carrier and to bring about a welding o the two layers of texture at their points of contact, after being pressed u on the carrier. Instead of asbestos also brous materials of another kind, such as cotton, hemp as well as brass wires or the like may be employed either singly or combined. It may eventually also be advisable to undercut or dove-tail the walls of the perforations 1, which of course need not be of circular conformation, in order to increase the adherence of the frictionalmass to the carrier especially in case only a onesided covering is rovided on the latter.

It will be imme iately apparent that with a frictional disc made according to this invention the available surface may be far better utilized than with the known :constructions, whereby only those parts of the frictional matrial will be effective which are positioned'within the perforations of the disc. A further advantage of the construction ac- Jend surfaces of said not in coherent pieces but in individual sector-shaped pieces, which supplement each other to form van almost closed annular surface practically fully covering the entire disc of sheet steel. The ring 11 is provided with a large number of groups of perforations. Each of these groups of perforations consists in the construction as represented of five perforations, of which the four smaller perforations 12 are positioned at or approximately at points which define a trapezoid, while a greater perforation 13 is provided at the center. The pieces 14 and 14a of the frictional covering are provided in pairs as may be seen from Figs. 5 and 6. The pieces 14 and 14a are of the conformation of a sector of an annular disc and are arranged one beside the other at relatively small peripheral distances.

According to the arrangement of the perforations 12 and 13 projections 15, 15a and 16 are provided on the opposite faces of the frictional members 14 and 14a. These projections are integral with the frictional members which are made from the above-mentioned materials and are formed on said members simultaneously with the latter. lThe height of the projections 15 and 15a is dimensioned in accordance with the thickness of the discshaped carrier 11A in such a manner that the rojections will abut against each other. he central projection 16, however, is made of essentially greater length, the length of this projection being about equal to the sum of the thicknesses of the disc-shaped'carrier and the thickness of the oppositely positioned pieces14a of the frictional covering. The piece 14a is provided at a point opposite the projection 16 with a proper bore with which sa1d projection comes in enga ement when assembling the device. The edges of the bores 12, 13 of the disc-shaped carrier are preferably somewhat rounded-off, as shown in Figs. 5 and 6.

The connection of the frictional members with the disc-shaped carrier is accomplished as follows: The frictional members which have been provided with the projections 15, 15a and 16 during the pressing of the impregnated fibrous material in cold condition before the hardening of the impregnating material takes place, are applied on either side bores of the oppositely positioned frictional members, the entire disc is placed into a hydraulic press and exposed to a heavy lpressure. In this condition now the hardening of the frictional material takes place as usual under developnent of heat, so that the oppositely positioned frictional members 14 and 14a fwill. be completely welded with eaclf other. Prior to applying the frictional members, the latter as well as the disc-shaped carrier 11 are preferably coated with the binding agent which is employed for making up the frictiona-ll material in order to render the connection between the frictional members and the disc-shaped carrier 11 as intimate as possible.

llt is of course not necessary to provide both frictional members of the co-operating pairs with projections which project exactly as far as tothe center of the disc-shaped carrier, as assumed in the represented construction. llnstead thereof the projections may, for instance, alternately passentirely through the bores of the disc-shaped carrier from the one or the other side of the latter. An 4essential feature of this construction consists therein, that said projections are so arranged that they are able to come in intimate Contact and unite with the material of the oppositely positioned frictional member.

li claim: 4

1. 'lihe method of forming frictional'bodies for clutches, brakes and the like which consists in providing acore plate with groups of perforations each group including a. central perforation .and marginal smaller perforations, providing preformed sections ofv plastic frictional material having marginal studs, one section having a vcentral opening, the other a central projection, applying said respective sections to the oppositesides of said core-plate to cause the studs to enter'the said marginal perforations of a group, and to cause the said projection on one section to pass through the central perforation-of the said group and through the said central opening of the opposite section, then welding the said sections so assembled to form a homogeneous mass interlocked through'said perforations and presenting frictional faces at the opposite sides of said core-plate.

'E A method, in combination with a foraminoussupporting plate,which consists in first pre-forming a plastic friction material mass into friction facing plates, and forming simultaneously therewith on one side of said facing plates a plurality of integral uniting projections, and .then assembling said plastic facing plates the integrally formed projections thereon in assembly with and through said foraminous supporting plate,

to unite said facing plates on opposite sides of and to the Isurfaces of said supporting plate and then fusing the preformed facing and foraminous plates into a homogeneous completely adherent mass.

3. The method of making brake rings and the like, consisting in providing a metal ring support `having perforations, preforming members of,frictional plastic material, and simultaneously providing substantially half of said members with a plastic unitary uniting projection and a corresponding hole in other members; passing said projection of one member through a hole in said metal ring support and through the hole in one of the said other members; then fusing said niem-` bers into a homogeneous mass to form opposite braklng surfaces.

4t. The method in combination with. a toc graminous plate, consisting 'in preforming members in pairs of plastic frictional material, one of said members being simultaneously preformed with an integral central long stud and shorter studs, the other of said plates of a pair, being pre-formed with a central opening and shorter studs assembling said members with the studs of each member extending through said plate, then uniting by fusing the shorter studs together and the said long stud into and with the op-v posite frictional member for forming a homo geneous mass having opposite friction surfaces.

5. The method of forming a brake member, which consists in forming a plate with openingsof dilerent sizes, preforming pieces of plastic frictional material each having studs to enter some of said openings, some pieces having centrally arranfred openings corresponding to the larger holes lin said plate, and some of said pieces having integral studs to enter the larger of said holes in said plate and through the said centrally arranged openings, then fusing the frictional material to form homogeneous masses, each rial adapted to pass through the said largerv holes of said Aplate and through the larger holes of said pieces, said uniting studs being integral with said pieces and in a plastic a homogeneous mass to form opposite brakmgsurfaces..

state, then uniting said pieces by into v 7. The method in combination with a foraminous supporting plate, which consists in preforming male and female friction members and providing simultaneousl with the .5 forming thereof with plastic stu to enter and unite in some of said holes in said ring, the male members being -further simultaneously formed with a central stud and the female members being further simultaneously 10 formed each with a central hole corresponding substantially in size and shape to said central studs', said shoe members when assembled with the `supporting plate and fused with the said central stud of one member 15 extending through the central hole of the other member forming braking surfaces on the opposite sides of said foraminous ring.

A In testimony whereof I 'aiiix m signature.

HANS KATTV7 INKEL. 

